Abstract:The three-level hybrid active neutral point clamped (3L-HANPC) converter has emerged as a preferred power conversion interface in modern energy systems due to its inherent advantages, such as high efficiency, high power density, and moderate cost. However, the reliability of such converters remains a pressing concern, primarily due to their susceptibility to switching faults. Among various fault-tolerant schemes, configuring shared redundant units is considered a cost-effective solution for three-level converters. It is mainly designed for T-type converters, and the redundant fully controlled devices typically operate in a standby state under normal conditions, resulting in low utilization of these components. This paper proposes a novel fault-tolerant 3L-HANPC converter and operating method that leverages the functional reuse of fully controlled redundant devices. In the proposed scheme, redundant devices are not limited to backup roles; instead, they actively contribute to system operation even under normal conditions, significantly improving device utilization and overall cost-effectiveness of the system. During normal operation, the shared redundant fully controlled devices and the DC inductor form a half-bridge ripple suppression unit. It compensates for the main low-frequency harmonic component in the neutral-point current, thereby reducing voltage ripples across the DC split capacitor under high modulation index and low power factor conditions. Furthermore, to simplify the control of the half-bridge ripple suppression unit, the circuit is decoupled into an upper and a lower buck converter, which are designed to operate in discontinuous conduction mode. The corresponding duty cycle expressions are derived. Then, a DC ripple suppression control block diagram is developed, utilizing a single-voltage PI feedback loop. When open-circuit faults occur in switches, the fully controlled devices in shared redundant units dynamically transition to a fault-bridge-sharing mode, enabling the cross-phase multiplexing of redundant devices. To ensure safe cross-phase multiplexing of redundant devices, the voltage vector sequence is restructured, and the corresponding circuit operating modes under typical vectors are analyzed. Additionally, the feasible operating region is defined based on the duty ratios of the voltage vectors. Accordingly, the converter can tolerate multiple switch open-circuit faults in different bridge arms while maintaining the rated output voltage magnitude. The paper provides a detailed description of the proposed topology, including its structural composition, operating mechanisms in normal and fault conditions, and the associated control strategies. A 10 kW 3L-HANPC converter prototype was constructed to conduct ripple suppression under normal conditions and fault-tolerant operation under fault conditions. The experimental results verify the correctness and effectiveness of the proposed topology and control method. The following conclusions can be drawn. (1) Under normal conditions, the redundant devices effectively suppress the DC-link voltage ripple by compensating for low-frequency harmonic components in neutral-point currents. The converter’s dynamic voltage regulation performance has been improved, with a measured ripple reduction exceeding 80%. (2) Under fault conditions, the redundant fully-controlled devices are shared among faulty bridge arms across different phases, enabling reliable fault ride-through of multiple switch open-circuit faults without the output voltage magnitude. The proposed fault-tolerant 3L-HANPC topology demonstrates significant applicability in high-reliability scenarios such as photovoltaic power generation and electric drive systems. It effectively mitigates the risk of substantial economic losses and safety hazards caused by switching faults.
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